Power tool including an anti-vibration handle

ABSTRACT

A power tool includes a tool operable to work on a workpiece, a drive mechanism coupled to the tool and operable to move the tool, a housing defining an interior, the drive mechanism disposed at least partially within the interior, and a handle having a first end and a second end. The first end is fixed to the housing and the second end is spaced apart from the housing to define a gap therebetween. An insert is fixedly attached to the housing and the second end to fill the gap. The insert is more flexible than the handle and the housing. The housing includes a first engaging portion and the handle includes a second engaging portion each engageable with the insert to substantially fixedly attach the insert to the housing and the handle, and the insert includes a third engaging portion, and a fourth engaging portion.

RELATED APPLICATION DATA

This application is a continuation of U.S. application Ser. No.13/542,740 filed Jul. 6, 2012 and issued as U.S. Pat. No. ______, theentire contents of which are incorporated herein by reference.

BACKGROUND

The present invention relates to anti-vibration handles. Morespecifically, the present invention relates to anti-vibration handlesfor use with power tools such as reciprocating saws.

Power tools often produce vibrations during use. These vibrations can becaused by the operation of the saw as well as the interaction with thetool and the work piece. The vibrations can pass through the power toolto the handle or handles and ultimately to the users hands. Thevibrations can cause fatigue or a reduced grip on the power tool makingits use less efficient and more difficult.

SUMMARY

In one construction, the invention provides a power tool that includes atool operable to work on a workpiece, a drive mechanism coupled to thetool and operable to move the tool, and a housing defining an interior.The drive mechanism is disposed within the interior. A handle has afirst end and a second end. The first end is fixed to the housing andthe second end is spaced apart from the housing to define a gaptherebetween. An insert is fixedly attached to the housing and thesecond end to fill the gap. The insert is more flexible then the handleand the housing.

In another construction, the invention provides a power tool thatincludes a tool operable to work on a workpiece, a motor coupled to thetool and operable to move the tool, a first housing, and a secondhousing coupled to the first housing to define an interior space. Themotor is disposed within the interior space. A handle includes a firstend fixedly attached to the first housing and a second end spaced apartfrom the first housing. An insert is fixedly attached to the firsthousing and the second end. The insert includes a first plurality ofcorrugations.

In another construction, a power tool includes a tool operable to workon a workpiece, a drive mechanism coupled to the tool and operable tomove the tool, a housing defining an interior, the drive mechanismdisposed at least partially within the interior, and a handle having afirst end and a second end. The first end is fixed to the housing andthe second end is spaced apart from the housing to define a gaptherebetween. An insert is fixedly attached to the housing and thesecond end to fill the gap. The insert is more flexible than the handleand the housing. The housing includes a first engaging portion and thehandle includes a second engaging portion each engageable with theinsert to substantially fixedly attach the insert to the housing and thehandle, and the insert includes a third engaging portion, and a fourthengaging portion.

In another construction, a power tool includes a housing that defines amain portion including an interior and a D-shaped handle having a firstleg that extends from the main portion and a second leg spaced apartfrom the main portion to define a gap. A drive mechanism is disposedwithin the interior and an insert is fixedly attached to the mainportion and the second leg to fill the gap. The insert is more flexiblethan the main portion and the D-shaped handle.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a power tool including an anti-vibrationhandle according to the invention;

FIG. 2 is a side view of an interior portion of one half of a power toolhousing having an insert positioned therein;

FIG. 3 is an enlarged perspective view of a portion of the housing ofFIG. 2 better illustrating the insert;

FIG. 4 is an exploded view of the portion of the housing and the insertof FIG. 3; and

FIG. 5 is a perspective view of the insert of FIGS. 2-4.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

The present invention provides a power tool 10 that includes ananti-vibration handle 15. While the invention is illustrated as appliedto a battery powered reciprocating saw, the invention could be appliedto conventionally powered (AC) reciprocating saws as well as other powertools that are battery powered or conventionally powered.

FIG. 1 illustrates the power tool 10 in the form of a reciprocating saw.The saw 10 includes a housing 20 and a handle 25 that extends from therear of the housing 20. The illustrated saw 10 is battery powered andtherefore includes a removable battery pack 30 that attaches to thehousing 20. A cutting tool 35 in the form of a saw blade extends fromone end of the housing 20 and is positioned adjacent a shoe 40. Duringuse, a user grasps the housing 20 in one hand and the handle 25 in theother. The shoe 40 is arranged to engage a workpiece while the saw blade35 reciprocates to cut the workpiece.

In preferred constructions, the housing 20 is formed from a firsthousing portion 45 and a second housing portion 50 that attach to oneanother to complete the housing 20. In other constructions, otherarrangements or arrangements with more than two housing portions areemployed.

FIG. 2 illustrates the first housing portion 45 with the second housingportion 50 removed. As can be seen, the first housing portion 45 and thesecond housing portion 50 cooperate to define an interior 55 thatcontains a motor 60 and a linkage or mechanism 65 that interconnects themotor 60 and the tool 35. It should be noted that in some constructions,the first housing portion 45 and the second housing portion 50 aresubstantial mirror images of one another. In other constructions, thesecond housing portion and the first housing portion are different fromone another. The construction illustrated and described herein includestwo housing portions 45, 50 that are substantial mirror images of oneanother. As such, the terms first housing portion 45, second housingportion 50, and housing 20 can be used largely interchangeably.

The first housing portion 45 includes a first engaging portion 70 thatis best illustrated in FIG. 4. The first engaging portion 70 includes apair of slots 80 that extend circumferentially around at least a portionof an opening 85 in the housing 20. FIG. 4 illustrates the slots 80 inthe first housing portion 45 with the second housing portion 50including similarly arranged slots 80.

The handle 25 is preferably formed from a first handle portion 90 and asecond handle portion 95 in a manner similar to that of the housing 20.FIG. 2 illustrates the first handle portion 90 of the handle 25 with thesecond handle portion 95 removed. The handle portions 90, 95 arearranged such that when assembled, they cooperate to define the D-shapedhandle 25. Of course other handle shapes and arrangements are possible.

The handle 25 includes a first end 100 and a second end 102 opposite thefirst end 100. The first end 100 is fixedly attached to the housing 20such that any relative movement therebetween is a result of materialflexing and resilience. In a preferred arrangement, the first handleportion 90 is formed as part of the first housing portion 45 and thesecond handle portion 95 is formed as part of the second housing portion50. A series of corrugations 104 are formed at the interface between thefirst end of the handle 100 and the housing 20 to increase theflexibility and relative movement available between the handle 25 andthe housing 20 at the first end of the handle 100.

The second end of the handle 102 is opposite the first end 100 and isspaced apart from the housing 20 to define a gap 106 therebetween. Thesecond end of the handle 102 includes a projection 105 that is part of asecond engaging portion 108. In the illustrated construction, theprojection 105 is cylindrical and extends in a direction that issubstantially normal to an axis of reciprocation 120 of the saw blade35. The second engaging portion 108 includes a cylindrical aperture 170,engaging slots 175, and a pair of pins 185.

An insert 125 engages the housing 20 at the first engaging portion 70and engages the handle 25 at the second engaging portion 108 to fill inthe gap 106 between the second end of the handle 102 and the housing 20.As illustrated in FIGS. 4 and 5, the insert 125 includes a thirdengaging portion 130, a plurality of corrugations 135, and a fourthengaging portion 140. The third engaging portion 130 includes a pair ofribs 145 that are sized and shaped to be received within the slots 80 ofthe first engaging portion 70. In other constructions, the firstengaging portion includes ribs and the third engaging portion includesslots. In still other constructions, other shapes and mechanisms areused to couple the insert 125 to the housing 20. The shape orarrangement is not critical so long as the first engaging portion 70 andthe third engaging portion 130 cooperate to fixedly attach the insert125 to the housing 20.

In the illustrated construction, three corrugations 135 are providedbetween the third engaging portion 140 and the second engaging portion130 to increase the flexibility of the insert 125. The corrugations 135are disposed within the gap 106 and allow for axial expansion as well astwisting motions between the handle 25 and the housing 20. In addition,the corrugations 135 assist in dissipating vibrations produced in thehousing 20 such that the vibration amplitude is reduced as it passes tothe handle 25.

The fourth engaging portion 140 extends from the corrugations 135 in adirection substantially opposite the third engaging portion 130 andincludes an extension 150, a pair of ribs 155, a pair of gussets 160,and a boss 165. The extension 150 includes a cylindrical portion that issized to fit within the cylindrical aperture 170 of the handle 25 toinhibit the unwanted entry of dirt, dust, or debris into the handle 25.The ribs 155 are size and shaped to engage the slots 175 formed in thehandle 25. The gussets 160 each include an aperture 180 that is sized toreceive one of the pins 185 positioned adjacent the cylindrical aperture170 of the handle 25. The boss 165 extends in a direction that issubstantially parallel to the reciprocation axis 120 and includes a slot190 having a long axis that extends along the same axis. The slot 190 issized to receive the projection 105 while still allowing movement of theprojection 105 with respect to the boss 165.

In preferred constructions, the handle 25 and the housing 20 are formedfrom a plastic material. In some constructions, a softer material may bepositioned over all or portions of the housing 20 and the handle 25 toimprove the grip of a user. In still other arrangements, these softerportions may be over-molded over portions of the housing 20 or thehandle 25. The insert 125 is preferably formed from a material that ismore flexible and/or softer than the housing 20 and the handle 25. Forexample, some constructions employ a rubber-like material to form theinsert 125.

To assemble the handle 25 and the housing 20, the first handle portion90 and the first housing portion 45 are preferably molded as a singlepiece with the gap 106 positioned between the second end of the handle102 and the housing 20. The second handle portion 95 and the secondhousing portion 50 are molded in a similar fashion. The insert 125 ispositioned within the first housing portion 45 and the handle 25, 90such that the first engaging portion 70 engages the third engagingportion 130. The fourth engaging portion 140 is then engaged with thesecond engaging portion 108 of the handle 25, 90 by engaging the gussetapertures 180 with the pins 185, engaging the ribs 155 with the slots175, and positioning the projection 105 within the slot 190 of the boss165. In this position, the corrugations 135 of the insert 125 aredisposed outside and between the housing 20 and the handle 25 in the gap106. The second housing portion 50, the second handle portion 95, andthe insert 125 engage one another in a manner similar to that justdescribed. The second housing portion 50 then attaches to the firsthousing portion 45 and the second handle portion 95 engages the firsthandle portion 90 to complete the assembly.

During use, the user positions the shoe 40 on a workpiece and actuates atrigger or otherwise activates the motor 60. The motor 60 drives theinterconnecting mechanism 65 that converts the rotary motion of themotor 60 to reciprocating motion of the saw blade 35. The rotating motor60, interconnecting mechanism 65, and the saw blade 35 interacting withthe workpiece produce vibrations at the housing 20. The vibrations movealong the housing 20 and pass to the handle 25. However, the slightrelative movement provided between the housing 20 and the handle 25 bythe insert 125 and the corrugations 104 dissipates the vibrations. Inaddition, the more flexible rubber-like material used to make the insert125 helps absorb vibrations.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A power tool comprising: a tool operable to workon a workpiece; a drive mechanism coupled to the tool and operable tomove the tool; a housing defining an interior, the drive mechanismdisposed at least partially within the interior; a handle having a firstend and a second end, the first end fixed to the housing, the second endspaced apart from the housing to define a gap therebetween; an insertfixedly attached to the housing and the second end to fill the gap, theinsert being more flexible than the handle and the housing, wherein thehousing includes a first engaging portion and the handle includes asecond engaging portion each engageable with the insert to substantiallyfixedly attach the insert to the housing and the handle, and wherein theinsert includes a third engaging portion, and a fourth engaging portion.2. The power tool of claim 1, wherein the drive mechanism includes amotor and is operable to move the tool in a reciprocating fashion. 3.The power tool of claim 1, wherein the housing includes a first portionand a separate second portion that attach to one another to define thehousing.
 4. The power tool of claim 1, wherein the insert includes aplurality of corrugations disposed between the third engaging portionand the fourth engaging portion.
 5. The power tool of claim 4, whereinthe corrugations are disposed within the gap.
 6. The power tool of claim1, wherein one of the first engaging portion and the third engagingportion includes a first slot and the other of the first engagingportion and the third engaging portion includes a first rib sized to bereceived by the first slot.
 7. The power tool of claim 6, wherein one ofthe second engaging portion and the fourth engaging portion includes asecond slot and the other of the first engaging portion and the thirdengaging portion includes a second rib sized to be received by thesecond slot.
 8. The power tool of claim 6, wherein the second engagingportion includes a second slot and a pair of pins and the fourthengaging portion includes a second rib sized to engage the second slotand a pair of gussets, each gusset including an aperture sized toreceive one of the pair of pins.
 9. The power tool of claim 1, whereinthe insert includes an extension that includes a slot, and the handleincludes a projection that is received by the slot such that theprojection is movable within the slot.
 10. The power tool of claim 1,further comprising a plurality of corrugations formed as part of thehandle and the housing and positioned adjacent the first end of thehandle.
 11. A power tool comprising: a housing that defines a mainportion including an interior and a D-shaped handle having a first legthat extends from the main portion and a second leg spaced apart fromthe main portion to define a gap; a drive mechanism disposed within theinterior; and an insert fixedly attached to the main portion and thesecond leg to fill the gap, the insert being more flexible than the mainportion and the D-shaped handle.
 12. The power tool of claim 11, whereinthe housing including a first side portion and a separate second sideportion, each of the first side portion and the second side portioncooperating to define the main portion and the D-shaped handle.
 13. Thepower tool of claim 11, wherein the main portion includes a firstengaging portion and the D-shaped handle includes a second engagingportion each engageable with the insert to substantially fixedly attachthe insert to the main portion and the D-shaped handle.
 14. The powertool of claim 13, wherein the insert includes a third engaging portion,and a fourth engaging portion including an extension.
 15. The power toolof claim 14, wherein the insert includes a plurality of corrugationsdisposed between the third engaging portion and the fourth engagingportion.
 16. The power tool of claim 14, wherein one of the firstengaging portion and the third engaging portion includes a first slotand the other of the first engaging portion and the third engagingportion includes a first rib sized to be received by the first slot. 17.The power tool of claim 16, wherein one of the second engaging portionand the fourth engaging portion includes a second slot and the other ofthe first engaging portion and the third engaging portion includes asecond rib sized to be received by the second slot.
 18. The power toolof claim 16, wherein the second engaging portion includes a second slotand a pair of pins and the fourth engaging portion includes a second ribsized to engage the second slot and a pair of gussets, each gussetincluding an aperture sized to receive one of the pair of pins.
 19. Thepower tool of claim 14, wherein the extension includes a slot and thehandle includes a projection that is received by the slot such that theprojection is movable within the slot.
 20. The power tool of claim 11,wherein the drive mechanism includes a motor and is operable to move thetool in a reciprocating fashion.